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SMOKE/ODOR

It is not uncommon to experience a small amount of smoke and odor
during the initial start-up. This is due to burning off of oil from metal parts,
and will disappear in a short while.

THERMAL EXPANSION

Water supply systems may, because of such events as high line
pressure, frequent cutoffs, the effects of water hammer among others,
have installed devices such as pressure reducing valves, check valves,
back flow preventers, etc... to control these types of problems. When
these devices are not equipped with an internal by-pass, and no other
measures are taken, the devices cause the water system to be closed.
As water is heated, it expands (thermal expansion) and closed systems
do not allow for the expansion of heated water.

The water within the water heater tank expands as it is heated and
increases the pressure of the water system. If the relieving point of the
water heater’s temperature-pressure relief valve is reached, the valve will
relieve the excess pressure. 

The temperature-pressure relief valve

is not intended for the constant relief of thermal expansion. 

This is

an unacceptable condition and must be corrected.

Closed systems require installation of a thermal expansion tank.
Failure to do so voids the limited warranty for this water heater.

STRANGE SOUNDS

Possible noises due to expansion and contraction of some metal parts
during periods of heat-up and cool-down do not represent harmful or
dangerous conditions.

Condensation causes sizzling and popping with the burner area during
heating and cooling periods and should be considered normal. See
“Condensation” in this section.

OPERATIONAL CONDITIONS

SMELLY WATER

In each water heater there is installed at least one anode rod (see
parts section) for corrosion protection of the tank. Certain water
conditions will cause a reaction between this rod and the water. The
most common complaint associated with the anode rod is one of a
“rotten egg smell”. This odor is derived from hydrogen sulfide gas
dissolved in the water. The smell is the result of four factors which
must all be present for the odor to develop:

a. a concentration of sulfate in the supply water.

b. little or no dissolved oxygen in the water.

c. a sulfate reducing bacteria within the water heater.  (This

harmless bacteria is non-toxic to humans.)

d. an excess of active hydrogen in the tank. This is caused by the

corrosion protective action of the anode.

Smelly water may be eliminated or reduced in some water heater
models by replacing the anode(s) with one of less active material,
and then chlorinating the water heater tank and all hot water lines.
Contact the local water heater supplier for further information
concerning an Anode Replacement Kit #9000029 and this
Chlorination Treatment.

If smelly water persists after anode replacement and chlorination
treatment, then the water supply must be chlorinated or aerated to
eliminate the bacteria.

DO NOT REMOVE THE ANODE LEAVING THE TANK
UNPROTECTED. BY DOING SO, ALL WARRANTY ON THE WATER
HEATER TANK IS VOIDED.

“AIR” IN HOT WATER FAUCETS

 WARNING

HYDROGEN GAS: HYDROGEN GAS CAN BE PRODUCED IN A HOT
WATER SYSTEM THAT HAS NOT BEEN USED FOR A LONG
PERIOD OF TIME (GENERALLY TWO WEEKS OR MORE).
HYDROGEN GAS IS EXTREMELY FLAMMABLE AND EXPLOSIVE.
TO PREVENT THE POSSIBILITY OF INJURY UNDER THESE
CONDITIONS, WE RECOMMEND THE HOT WATER FAUCET BE
OPENED FOR SEVERAL MINUTES AT THE KITCHEN SINK
BEFORE ANY ELECTRICAL APPLIANCES WHICH ARE CONNECTED
TO THE HOT WATER SYSTEM ARE USED (SUCH AS A
DISHWASHER OR WASHING MACHINE). IF HYDROGEN GAS IS
PRESENT, THERE WILL PROBABLY BE AN UNUSUAL SOUND
SIMILAR TO AIR ESCAPING THROUGH THE PIPE AS THE HOT
WATER FAUCET IS OPENED. THERE MUST BE NO SMOKING OR
OPEN FLAME NEAR THE FAUCET AT THE TIME IT IS OPEN.

VENTING MANUAL RESET SWITCH

There is a venting manual reset switch located on top of the venting
hood. If the switch is activated, before resetting the switch, check for
flue blockage in the venting system. To reset, press the red button.

HIGH TEMPERATURE SHUT OFF SYSTEM

This water heater is equipped with an automatic gas shut off
system. This system works when high water temperatures are
present.

E.C.O.

The E.C.O. will activate if the water temperature exceeds 200°F and will
not reset itself. If it is activated, contact a service agent to determine the

cause.

 WARNING

Should overheating occur or the gas supply fail to shut off,

turn “off” the manual gas control valve to the appliance.

NOT ENOUGH OR NO HOT WATER

1. Check the manual gas shut off valve to be sure it is open.

2. Check the pilot flame. It may have gone out. All models have an

opening behind the outer door for viewing the pilot.

3. If the pilot is not lit, follow the “Lighting” instructions in this manual or

located above the gas control valve on the water heater to relight the

Summary of Contents for PREFERRED BPD 400

Page 1: ...not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department Installation and service must be performed by a qualified installer service agency or the gas supplier AOS PREFERRED BPD400 DIRECT VENT COMMERCIAL GAS WATER HEATER GAS FIRED INDUCED DRAFT FOR DOMESTIC HOT...

Page 2: ...PACITIES NATURALGAS Input Capacity TEMPERATURE RISE DEGREES F GALLONS PER HOUR LPH BTU Gallon 30 F 40 F 50 F 60 F 70 F 80 F 90 F 100 F 110 F 120 F 130 F 140 F Model kw Hr Liters 17 C 22 C 28 C 33 C 39 C 44 C 50 C 56 C 61 C 67 C 72 C 78 C BPD 400 390 000 95 1316 987 789 658 564 493 439 395 359 329 304 282 114 3 360 4981 3735 2988 2490 2135 1868 1660 1494 1358 1245 1149 1067 Recovery capacities are ...

Page 3: ...ODES SHUTOFFVALVE COLD WATER INLET MIXING VALVE TEMPERED WATER OUTLET HOT WATER OUTLET GAS SUPPLY Installation Information for Model BPD 400 100 Series ELECTRICAL CLEARANCES PRESSURES ORIFICES INPUT 120 24VAC 60Hz 5A FRONT SIDES TOP NATURAL NATURAL NATURAL 390kbtuh UNIT IS POLARITY SENSITIVE 6 15 cm 0 12 30 5cm Manifold 4 50 WC Sea Level 0 126 Inlet 7 00 WC 4500 0 126 Max Inlet 14 00 WC 8000 0 106...

Page 4: ...ended Nonuse Periods 5 Insulation Blankets 5 High Altitude Installations 5 FEATURES 6 The Eliminator 6 High Limit Switch E C O 6 Circulating Pump 6 Dishwashing Machine Requirement 6 Electronic Ignition Control 7 Pilot Assembly 7 Gas Valve 7 Pressure Switch 7 Step Down Transformer 8 Burner Tray Assembly 8 Burner Tray 8 Burner 8 Burner Orifice 8 Blower Assembly 8 High Limit Switch 9 Shroud Assembly ...

Page 5: ... 1 FAILURE TO REPLACE THE ORIFICES WILLRESULT IN IMPROPERAND INEFFICIENT OPERATION OF THE APPLIANCE RESULTING IN THE PRODUCTION OF INCREASED LEVELS OF CARBON MONOXIDE GAS IN EXCESSOFSAFELIMITSWHICHCOULDRESULTINSERIOUSPERSONAL INJURY OR DEATH You should contact your gas supplier for any specific changes which may be required in your area As elevation above sea level is increased there is less oxyge...

Page 6: ...RE1 HIGH LIMIT SWITCH E C O The dual bulb controller contains the high limit energy cutoff sensor see Figure 2 The high limit switch interrupts main burner gas flow should the water temperature reach 205 F 96 C In the event of high limit switch operation the appliance cannot be restarted unless the water temperature is reduced by at least 20 F 11 C and the high limit reset button on front of limit...

Page 7: ... deliver water between these limits The National Sanitation Foundation also recommends circulation of 180 F 82 C water Where this is done the circulation should be very gentle so that it does not cause any unnecessary turbulence inside the water heater The circulation should be just enough to provide 180 F 82 C water at the point of takeoff to the dishwashing machine Adjust flow by means of the pl...

Page 8: ...NER TRAY The burner tray holds the burners in place and is used to slide the entire assembly into the combustion chamber BURNERTRAY BURNER The appliance is equipped with 8 burners mounted in a burner tray assembly The burners are tubular in design with two rows of small slit burner ports The natural gas burners are made of aluminized steel and the LP version is a stainless steel material TUBULAR B...

Page 9: ...LES ARE STORED OPERATED OR REPAIRED FLAMMABLE VAPORS ARE HEAVY AND TRAVEL ALONG THE FLOOR AND MAY BE IGNITED BY THE HEATER S PILOT OR MAIN BURNER FLAMES CAUSING FIREOREXPLOSION SOMELOCALCODESPERMITOPERATIONOFGAS APPLIANCES IN SUCH AREAS IF THEY ARE INSTALLED 18 OR MORE ABOVE THE FLOOR THIS MAY REDUCE THE RISK IF LOCATION IN SUCH ANAREACANNOT BEAVOIDED DONOTINSTALLTHISWATERHEATERDIRECTLYONACARPETED...

Page 10: ...g shall have a free area of at least one square inch per 1000 Btuh 2 225mm Kw of the total input of all appliances in the enclosure but not less than 100 square inches 645 square cm If the confined space is within a building of tight construction air for combustion ventilation and draft hood dilution must be obtained from outdoors When directly communicating with the outdoors or communicating with...

Page 11: ...LVESOROTHERGASREGULATINGEQUIPMENT WARNING FAILURETO HAVE REQUIRED CLEARANCES BETWEEN WATER HEATER AND COMBUSTIBLE MATERIALWILLRESULT IN AFIRE HAZARD FIGURE 7 FACTS TO CONSIDERABOUT THE LOCATION VENTING THROUGH ROOF CLEARANCES 1 2 5 cm clearance for 4 or 6 PVC or CPVC piping from combustible surfaces for outlet piping 0 clearance for 4 or 6 PVC or CPVC piping from combustible surfaces for inlet pip...

Page 12: ...LVE S SHALL NOT BE LESS THAN THE COMBINED BTU INPUT TO THE WATER HEATER S SUPPLYING WATER TO THE STORAGE VESSEL S THERMOMETERS Not Supplied Thermometers should be obtained and field installed as shown in the installation diagrams Thermometers are installed in the system as a means of detecting the temperature of the water in the appliance TEMPERATURE PRESSURE RELIEF VALVE This water heater is equi...

Page 13: ...R THAN THE ONE SHOWNABOVE FAILURE TO USE THE CORRECT VOLTAGE CAN CAUSE PROBLEMS WHICH CAN RESULT IN DEATH SERIOUS BODILY INJURY OR PROPERTY DAMAGE IF YOU HAVE ANY QUESTIONS OR DOUBTS CONSULT YOUR ELECTRIC COMPANY CAUTION IF WIRING FROM THE FUSE BOX OR CIRCUIT BREAKER BOX WAS ALUMINUM FOR THE OLD WATER HEATER REPLACE IT WITH COPPER WIRE IF YOU WISH TO REUSE THE EXISTINGALUMINUM WIRE HAVE THE CONNEC...

Page 14: ...ith the water heater must be replaced it must be replaced with 105 C thermoplastic AWM wire or its equivalent CAUTION LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION VERIFY PROPER OPERATION AFTER SERVICING MINIMUM LINE VOLTAGE WIRE NO 14 AWG ...

Page 15: ...R REFRIGERANTS SWIMMING POOL CHEMICALS CALCIUM AND SODIUM CHLORIDE WAXES BLEACH AND PROCESS CHEMICALS ARE TYPICAL COMPOUNDS WHICH ARE POTENTIALLY CORROSIVE Horizontal runs must be securely supported at 3 1 2 foot intervals and vertical runs supported at 5 foot intervals VENTING THROUGH AN OUTSIDE WALL Items supplied in the carton 1 One 4 inlet PVC Schedule 40 45 vent cap with screen 2 One 4 outlet...

Page 16: ...EM EXAMPLE INSTALLATIONS FOR ALL MODELS The vent piping cannot under any circumstances be run downhill THE VENT PIPING CAN BE INSTALLED AS FOLLOWS 1 Horizontal runs require a minimum 1 8 3 mm rise per five feet 2 The total vertical and horizontal run cannot exceed the maximum length with number of 90 elbows as specified in the tables below If more elbows are required the venting distance must be r...

Page 17: ...it 3 Clean pipe and fitting with a primer cleaner 4 Apply a thin coat of cement to fitting avoiding puddling inside 5 Apply a liberal coat of cement to pipe leaving no voids 6 QUICKLY assemble parts while cement is fluid If you wait too long recoat pipes 7 Push pipe completely into socket of fitting turning as it goes until it bottoms 8 Hold pipe and fitting together for 30 seconds Then carefully ...

Page 18: ... wall of combustible construction CONNECTING VENT TO BLOWER 4 VENT PIPING 1 If making an immediate horizontal run of vent off the blower the 6 15 cm to 4 galvanized steel reducer and a PVC Schedule 40 street elbow are required for the inlet pipe and the 6 to 4 reducer and two CPVC Schedule 40 or 80 street elbows are required for the outlet vent Place the elbows in the required direction on the red...

Page 19: ...ule 40 or 80 elbow is then cemented on to the end of the 4 pipe section CPVC Schedule 40 or 80 pipe for the first ten feet is then cemented to the upturned elbow VENTINGTHROUGHAROOF Items supplied in the carton 1 One 4 inlet PVC Schedule 40 45 vent cap with screen 2 One 4 outlet CPVC Schedule 80 45 vent cap with screen 3 Two 6 to 4 galvanized steel reducers 4 Two wire screens to fit one each 6 PVC...

Page 20: ...of 1 2 pound per square inch 3 5kPa The appliance must be isolated from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1 2 pound per square inch 3 5kPa WARNING Contaminants in the gas lines may cause improper operation of the gas control valve that may result in fire or ...

Page 21: ...NS FOR MODEL 100 400 BEFORE OPERATINGTHEWATERHEATER 1 Review the installation and instruction manual before turning on the electric power and gas supply to the water heater to safeguard against a possible dangerous malfunction of the water heater 2 The electrical supply to this water heater must NOT be turned on before the tank is completely full of water the gas supply is available and the ventin...

Page 22: ...the venting manual reset switch and on to theignitionmodule The ignition module will then complete a circuit simultaneously to the spark ignitor and to the gas pilot valve solenoid The spark ignitor will begin sparking and the gas pilot solenoid will open allowing gas to pass to the pilot When a pilot flame has been established the flame sensor in the pilot burner assembly will signal the ignition...

Page 23: ...ss cover 4 Set the thermostat to lowest setting 5 This appliance is equipped with an ignition device which automatically lights the pilot Do not try to light the pilot by hand 6 Turn knob on gas control clockwise to OFF position 7 Wait five 5 minutes to clear out any gas If you then smell gas STOP Follow B in the safety information above on this label If you do not smell gas go to the next step 8 ...

Page 24: ... F 49 C to 180 F 82 C SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF TURN OFF THE MANUAL GAS CONTROL VALVE TO THE APPLIANCE START UP CONDITIONS CONDENSATION Whenever the water heater is filled with cold water a certain amount of condensation will form while the burner is on A water heater may appear to be leaking when in fact the water is condensation This usually happens a When a new...

Page 25: ...ria is non toxic to humans d an excess of active hydrogen in the tank This is caused by the corrosion protective action of the anode Smelly water may be eliminated or reduced in some water heater models by replacing the anode s with one of less active material and then chlorinating the water heater tank and all hot water lines Contact the local water heater supplier for further information concern...

Page 26: ...NT SYSTEMS MAY PRESENTSERIOUSHEALTHRISKORASPHYXIATION WARNING CHEMICAL VAPOR CORROSION OF THE FLUE AND VENT SYSTEM MAY OCCUR IF AIR FOR COMBUSTION CONTAINS CERTAIN CHEMICAL VAPORS SPRAY CAN PROPELLANTS CLEANINGSOLVENTS REFRIGERATORANDAIRCONDITIONER REFRIGERANTS SWIMMING POOL CHEMICALS CALCIUM AND SODIUM CHLORIDE WAXES BLEACH AND PROCESS CHEMICALS ARE TYPICAL COMPOUNDS WHICH ARE POTENTIALLY CORROSI...

Page 27: ... PRESSURE RELIEF VALVE WITH A NEW ONE WARNING IF THE TEMPERATURE PRESSURE RELIEF VALVE ON THE APPLIANCE WEEPS OR DISCHARGES PERIODICALLY THIS MAY BE DUE TO THERMAL EXPANSION YOUR WATER HEATER MAY HAVE A CHECK VALVE INSTALLED IN THE WATER LINE OR A WATER METER WITH A CHECK VALVE CONSULT THE WATER SUPPLIER AND OR PLUMBING CONTRACTOR FOR FURTHER INFORMATION DO NOT PLUG THE TEMPERATURE PRESSURERELIEFV...

Page 28: ...OT WATER SUPPLIED TO FIXTURES PIPE TO OPEN DRAIN INSTALL IN ACCORDANCE WITH LOCAL CODES INSTALLATION DIAGRAMS CAUTION IF BUILDING COLD WATER SUPPLY HAS A BACK FLOW PREVENTER CHECK VALVEORWATERMETERWITH CHECK VALVE PROVISIONS FOR THERMALEXPANSION OF WATER IN THE HOT WATER SYSTEM MUST BE PROVIDED NOTE CONNECT RETURN LINE FROM HOT WATER CIRCULATING LOOP IF USED TO COLD WATER INLET LINE PIPE TO OPEN D...

Page 29: ...R TEMPERATURE SETTING SHOULD NOT EXCEED SAFE TEMPERATURE AT FIXTURES SEE WATER TEMPERATURE CONTROL WARNING ON PAGE 24 IF HIGHER PREHEAT TEMPERATURES ARE NECESSARY TO OBTAIN ADEQUATE BOOSTER OUTPUT ADD AN ANTI SCALD VALVE FOR HOT WATER SUPPLIED TO FIXTURES CAUTION IF BUILDING COLD WATER SUPPLY HAS A BACK FLOW PREVENTER CHECK VALVE OR WATER METER WITH CHECK VALVE PROVISIONS FORTHERMAL EXPANSION OF W...

Page 30: ...LD KIT SPECIFICATIONS PAGE33 CAUTION IF BUILDING COLD WATER SUPPLY HAS A BACK FLOW PREVENTER CHECK VALVE OR WATER METER WITH CHECK VALVE PROVISIONS FOR THERMALEXPANSION OF WATER IN THE HOT WATER SYSTEM MUST BE PROVIDED DANGER TEMPERATURESETTINGSHOULDNOTEXCEEDSAFETEMPERATUREAT FIXTURES SEEWATERTEMPERATURECONTROLWARNINGONPAGE24 IF HIGHER PREHEAT TEMPERATURES ARE NECESSARY TO OBTAIN ADEQUATE BOOSTER ...

Page 31: ...ONNECTCIRCULATINGLINEOF180 F 82 C ORBOOSTEDWATER IF USED TO INLETWATER LINETO BOOSTER INSTALL INACCORDANCE WITH LOCALCODES TWO TEMPERATURE TWO HEATERS ONE PRE HEATER ONE BOOSTER HEATER WITH OR WITHOUT BUILDING RECIRCULATION DANGER TEMPERATURESETTINGSHOULDNOTEXCEEDSAFETEMPERATUREAT FIXTURES SEEWATERTEMPERATURECONTROLWARNINGONPAGE24 IF HIGHER PREHEAT TEMPERATURES ARE NECESSARY TO OBTAIN ADEQUATE BOO...

Page 32: ...NTHETANK NOTE4 IFTEMPEREDWATERISRECIRCULATED RETURNLINESHOULD BE CONNECTEDATPOINTA DANGER TEMPERATURESETTINGSHOULDNOTEXCEEDSAFETEMPERATUREAT FIXTURES SEEWATERTEMPERATURECONTROLWARNINGONPAGE24 IF HIGHER PREHEAT TEMPERATURES ARE NECESSARY TO OBTAIN ADEQUATE BOOSTER OUTPUT ADD AN ANTI SCALD VALVE FOR HOT WATERSUPPLIEDTOFIXTURES CAUTION IF BUILDING COLD WATER SUPPLY HAS A BACK FLOW PREVENTER CHECK VAL...

Page 33: ...ter heating and storage potential of the system cannot be achieved Plus the units with the higher water flow may have a shortened life Unions shown in piping diagrams are not included in the manifold kits Dimensions shown are for minimum space occupied by the water heaters assemblies Space for the venting system and unit servicing must be added ...

Page 34: ...ically for lime scale removal from all types of water using equipment Available in 1 gallon 3 8L part no 4763 and 5 gallon 19L part no 4813 sizes Hydrochloric base acids are not recommended for use on glass lined tanks A O Smith Form No 4800 entitled Why When and How describes tank cleaning methods and materials UN LIME and the booklet may be obtained through your A O Smith dealer or distributor T...

Page 35: ... to unless an effective method of controlling thermal expansion is also installed at the heater s and operational at all times The relief valve installed on the heater is not an acceptable method 4 SERVICEANDREPAIREXPENSES Under the limited warranty the warrantor will provide only a replacement water heater or part thereof The owner is responsible for all other costs Such costs may include but are...

Page 36: ...36 A O SMITH WATER PRODUCTS CO 500 Tennessee Waltz Parkway Ashland City TN 37015 PHONE 1 800 433 2545 FAX 1 800 433 2515 www hotwater com email parts hotwater com ...

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